Multi-roll bonding and aperturing

Abstract

A method and apparatus for bonding and aperturing one or more fibrous webs including bonding at least one fibrous web in a bonding nip created by a rotatable bonding roll and a rotatable anvil roll and aperturing the at least one fibrous web in an aperturing nip created by a rotatable aperture roll and an anvil roll. The bonding roll has a plurality of protuberances extending from the peripheral bonding surface that define a bonding pattern and result in highly bonded regions within the fibrous web. The aperture roll has a plurality of projections extending from the peripheral aperture surface that define an aperturing pattern. The aperturing pattern substantially aligns with the bonding pattern thereby creating apertures within the highly bonded regions.

Description

BACKGROUND OF THE INVENTION [0001] This invention generally relates to fibrous webs and fibrous web laminates suitable for use in articles used to absorb, distribute and retain body liquids, such as disposable diapers, sanitary napkins, incontinence garments, and the like, and to a method and apparatus for making the same. [0002] Nonwoven materials, such as spunbonded webs and carded webs, have been used as bodyside liners in disposable absorbent articles. Typically, very open, porous liner structures have been employed to allow liquid to pass through them rapidly, thereby keeping the wearer's skin separate from the wetted absorbent core underneath the liner. Also, other layers of material, such as those constructed with thick, lofty fabric structures, have been interposed between the liner and absorbent pad for the purposes of handling surges of liquids and reducing flow back of liquids. [0003] Previous methods and apparatus for aperturing nonwoven webs, which have been used as bod...

AI Technical Summary

Benefits of technology

[0006] In response to the needs discussed above, the present invention provides a method and apparatus for bonding and aperturing one or more fibrous webs, the resultant bonded and apertured one or more fibrous webs and absorbent articles incorporating the resultant bonded and apertured one or more fibrous webs.

Problems solved by technology

Previous methods and apparatus are less effective when aperturing lofty or thick nonwovens because the apertures tend to close once the projections are removed from the lofty web.

Additionally, tension in the lofty nonwoven web also tends to close the apertures made by traditional methods and apparatus.

Finally, previous methods and apparatus tend to compress the entire fibrous nonwoven web.

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